Casting and method of making the same



Jan. 14, 1930. H. PERRY 1,743,567

CASTING AND METHOD OFMAKING THE SAME Filed July 24, 1926 I ff? @j f4 w 22,. M1

ATTORNEY /Patented Jan. 14, 1930 UNITED STATES Hanny runny, or BBooxLY'N,

Nirrizur olv-"Fler:

NEW YORK, ASSIGNOB 0F ONE-HALF TO JOHN I. COLE,

`02E? NEW YORK, N. E. i

CASTING AND METHOD OF'MAKJNG THE SAME Application led July 24, 192?. Serial No..124,761.

are of small diameter, are curved, or have considerable length, it is very difficult and sometimes impossible to make castings in the ordinary manner and provide the cored hole.

The longer braces and arms are frequently made of tubing bent to shape, while the sh0rter parts may be cast to have a wire receiving groove which may be covered in some manner to hide the wires, or hollow parts maybe made by slush casting.

The present invention contemplates the manufacture of castings suitable for these or analogous uses wherein a smooth, curved, or straight hole is provided. Accordingly, a suitable length of ilexible steel tubing of the proper diameter is placed in the molds before the molten metal is poured. lThe metal used has a melting point below that of the steel in the tubing, and after the metal has cooled around the flexible tubing, the casting with the tubing included on it is removed from the mold. The tubing remains in the casting and provides the hole desired, as well as greatly stiiening the casting and render@ ing it less liable to breakage from shock.

A further object of the present invention is to provide an improved process of making castings of this sort wherein the molten metal is effectively kept from entering the hollow tubing, and whereinthe castings may be provided with any desired surface ornamentation and may be readily made with intricate curves. Y

A further object -of the invention is to provide a method of making hollow castings out of white metal in forms and shapes which cannot ordinarily be made in hollow form from this material, but which have heretofore v an arrangement of molds for making been made of brass, bronze or more expensive alloys.

A further object of the invention is to provide castings of the nature above referred to wherein smooth uniform holes of the desired diameter are provided for wiring, oil circulation or the like.

The accompanying drawings show, for

purposes of illustration, a` casting made ac.

cording to the present invention as well as such castings, it being understood that the drawings are illustrative of the invention rather than limiting the same. Y

ln these drawings: Figure l is a side elevational view, with parts in section, showing a casting, such as a lighting fixture arm, made according to the present method;

Figure 2 is a view showing vone half of a two part mould with the core and holding devices for the core in position;

Figure 3 is a sectional view through the mould, casting and core and showing one construction or supporting the core in position;

Figure i is a rear view with parts in section, showing a method of utilizing the ilexible core in a two-arm wall bracket; and

' Figure .5 is a vertical sectional view through a different form of lighting fixture backplate showing a further use of the exible core. Y

Figures l and 2 illustrate the manufacture of a short curved casting, such -as a, lighting While the drawing shows a simple curved arm, it is of courseunderstood that this is merely for illustration as arms may have various curves. Instead of making a casting which curves in one plane only, it is of course obvious that the casting could be curved in various planes.

One half of a bronze mould for making such a casting is indicated at 10 in Figure 2. This mould, together with the companion mould, will be made up according to the conventional manner for the design of the article to be produced. The flexible core will be supported in one half of the mould and the ot er half placed in position and clamped,

whereupon the molten metal will be in the usual manner. As here shown, one en 11 of the core 12, consisting of a length of flexible steel tubing, is supported from the mould b means of a plu or end member 13 removabl mounted in themould held in place by pins 14. As illustrated 1n the drawing, this lug member has a reduced portion 15, whi e a further reduced end portion 16 fits inside the flexible tubin At the other Aend of the mould, a removab e p lug or end member. 17 is suitably anchored 1n the mould by means of pins 18. As here shown, this plug member 1s threaded as indicated at 19 to receive a threaded nip le 20. The plug member 17 also has a sha t portion 21 adapted to pass through the inside of the nipple 20 and extend beyond the end of the nipple so as to support the other end 22 of the flexible steel core 12. l

In some cases, the arms will be so long that the ilexible core will tend to fall away fromv the center of the mould. f In such cases, the

u se a coiled wire su port 24 which 'is wound .p

Vmolten metal into the nipple inserted, if desired. The sup core may be held in place by a bent wire saddle such as is indicated at 23 in Figures 2 and 3. This saddle willbe anchored in one of the moulds and will be shaped to hold. the core in place. In otherinstances, the core may tend to come to one side of the center of the mould and to overcome this, onemay around the core an anchored in the mould, as indicated. Y

Assuming that the core,"end members and core-supports have been inserted in the mould as above described, and that the mould has been closed and clamped, one then brings the mould to the proper position to pour the ate, indicated at 25.

The metal will then ll the mould in the usual fashion solidifying about'` the core.V

removed from the mould. These plug4 ory end members 13 may be separatedfrom the casting in the usual manner and the end member 17 will be unthreaded' from the nipple. These end members will have revented the flow of metal into the inside o the core and one therefore obtains acastin with a smooth core made out of a length o tubing. The nipple 20 will have been anchored properly in the casting. The hole left in the casting by the portion 15 may be tapped and a rtS 23 and 24 if used, may be snipped and t e casting finished in the usual manner.

igure 4 illustrates one form of lighting fixture bracket utilizing the flexible core in the arms. Here the main art or bac indicated at 30, is recessed y the moul used in making this part of the Icastin or itmay be produced in a slush mould. e lower or the solid center of the` bracket.

late,

narrow part of the backplate 31 is preferably cast in a two part moul a length of exible tubing 32 extending acrossfthe mould and being suitably anchored. The parts are so ared that the tubing is laced in the center df t e'arms 33 and 34. It extends throu' h After t e bracket has been cast, one may drill a hole 35 into the flexible steel tubing.' It is also possible to make the moulds so that the cast- 1 ho ow part of the backplate to the drilled hole 35 so that lead wires may lie. in the channeland pass through the hole into the tubing and thence to the ends of the arms and the sockets to be mounted thereon.

Lighting fixture backplates and Wall brackets are also made with narrow or neck portions which are immediately above the arms. Such a bracket is illustrated in Design Patent No. 64,078, granted February 26, 1924. This narrow portion is further weakened because it has been customary to cut it away in the back to allow the wires to pass down to the arms to supply current to the lamps. Figure 5 illustrates a reinforcement of such a backplate 40 by means of a length has a channel 36 leading down from the of tubing 41 which is placed in the casting so reinforces the backplate and makes this part of the casting so strong that breakage is very unlikely.

From the fore oing, it will be apparent that by the use o lengths of exible tubing as a core for white metal castings, one can construct such castings so as to be exceedingly strong and rug ed. The flexible steel core can be bent into s apes which are ver dilicult and almost impossibleto obtain wit sand cores. The castings will be strong and uniform and one can provide wire passages with .out relying on slush casting processes.

It is obvious that the invention may be embodied in many forms and constructions, and

fthe method can be carried out in various manners, and I Wish it to be understood that the particular forms shown and steps set forth are illustrative of the many possible ones. Various modifications and changes being pos sible, I do not limit myself in any way .with respect thereto. The method may be employed in making iron castings where one desires curved holes, such as oil passages.

I claim: l l

1. A casting having a hollow core in the form of a length of flexible steel tubing and an outer layer of metal of lower melting point intimately united with the steel tubing, and a tubular threaded coupling member about which the end of the casting is formed, the inner end of the coupling member being adjacent the end of the tubing, the coupling late. This length of steel tubing materially the coupling member cooperating with the 3. The method of making castings with curved cores, which comprises forming a suitrod through a tubular threaded coupling member and into one end of thetubing, the plug and coupling member cooperating with the mould when closed to hold the end of the tubing in place and to prevent'the entrance of molten metal into the tube, and pouring the molten metal into the mould. v

HARRY PERRY.

able length of readily flexible wound steel tubing to the desired shape, lacing the tubing in a mould with the en sof the tubing plugged to prevent moltenmetal flowing into the tube,and pouringmolten metal into the mould.

4. The method of making castings with curved cores, which comprises insertin plugs into the ends of a length of readily exible wound steel tubing preformed to the desired shape, placing the tubing and plugs in a mould so that the tubing'is positioned where the core is desired, closinv the mould, pouring the molten metalinto the mould, removing the casting with the tubing encasedtherein and then removing the flugs'.

5. In the making o a casting, having a curved cored passage, the process which comprises suitably lacing in prepared moulds a length of rea ily flexible wound steel tub! ing preformed to have the configuration of the desired passage, providing means for preventing molten metal from entering the tubing, and pouring the molten metal into the moul 6. rlfhe method of making cast lighting fixture amis or the like havlng curved cores, which comprises the placin 1n one part of a metal mould of a length o readily flexible Wound steel tubing preformed to the desired shape and havin a removable plug placed in the end thereof, t e plug cooperating with the mould, when closed, to hold the end of the tubing in place and to prevent the entrance of molten metal into'the tube, and pouring the molten metal into the mould.

7 The method of making cast lighting fixture arms or the like, whlch comprises the placing in one art of a metal mould of a length of flexib e steel tubing in the end of which is placed a removable plug passing a rod through a tubular threaded coupling member and into the other end of the tubing,

` mould when closed to hold the tubing in place and to prevent the entrance of moltenmetal into the tube, and pouring the molten metal into the mould.

8. The method of making cast lighting fixture arms or the like, whlch comprises the placing in one part of a metal mould of a length of flexible steel tubing in the end ofwhich is placed a removable plug, passing a 

